Brushless ipm motor design using flux 2d dedicated motor template overlay used to create and mesh easily the device. Therefore the designers face a lot of difficulties in designing and optimizing the motor for a. Evo axial flux electric motors have one of the highest usable power and torque densities of any electric vehicle drive motor available on the market today. I have a understanding of bldc motors and now would like to design and make my own motor. Pdf generalized procedure for bldc motor design and. Design and analysis of axial flux permanent magnet bldc motor for automotive applications, ieee international conf. For an ev with even modest performance, such a motor can weigh well over 100 pounds. Therefore the designers face a lot of difficulties in designing and optimizing the motor for a given. This paper presents the design of an electric motor for the direct drive of electric vehicle. The evo permanent magnet axial flux motors are based on proprietary and patented technology that.
This results in a fill factor as high as 90%, again improving. Yasas proprietary axial flux motors are smaller and lighter than any other motors in their class due to our more efficient use of key magnetic and structural materials. Permanent magnet brushless dc motor, design and its dynamic performance analysis is done on. I am designing a axial flux interior mkagnet bldc motor pancake. Magnax supports the global cleantech evolution by innovating in nextgeneration axial flux electric motor technology for electric vehicles. Fluxmotor is a flexible software solution dedicated to the pre design of electric motor. For equations of voltages of the axial flux permanent magnet synchronous generator the threephase stator windings have been written as 1 v s 1, abc r s 1, abc. Design and fabrication of axial flux ferrite magnet brushless dc motor for electric twowheelers presented by muhammed fasil. Design of axial flux permanent magnet brushless dc motor for. The motor was fabricated and constructed on a testbed. On a radial flux bldc motor, the magnets are positioned such that their. These motors incorporate a unique stator and rotor design with surface mounted permanent magnets to deliver high power at efficiencies far superior to highperforming induction motors.
The yasa yokeless and segmented armature motor topology also significantly reduces manufacturing complexity, making the motors ideally suited to. A radial flux motor has its flux running in and out from the center of the shaft on the radius thus, radial. Design and analysis of a new axial flux coreless pmsg with. After successfully building a brushless controller i have decided also to build my own brushless motor. Because the axial flux motors are short in length, they could be used on a chassis or inside of a wheel as a. Brushless motors, bldc motor, sensorless motor, motor. A new generation of axial flux ev motors design news. The result is a motor concept which is characterized by a high power density and robustness. The company uses a rectangular section copper to wind its stator. A new generation of axial flux ev motors a startup belgian company wants to join the ev world with its new axial flux motor design. We have over 75 years of expertise in providing innovations to the hvac industry in ecm, axial and radial flux motor technology, vfds, bearings, sheaves, and belts. There are a lot of subtleties to designing blpm motors, some not immediately obvious, particularly if you want an ipm motor with wide field weakening or something.
Brushless ipm motor design using flux 2d dedicated motor. For axial flux motor you will need to go into 3d fea. The axial flux bldc motors are relatively new, specially at higher power ratings over 10kw. Lappeenranta university of technology isbn 9522140295, isbn 9522140309 pdf, issn 14564491. This paper presents a new method to optimize the performance in speed, torque, torque stability, power output, power density and motor dimensions in view of the cost and. Before start to design something you need to know the rpm needed,torque needed,running voltage, max amps. Brushless dc motor for solar vehicle using ansys software. Join our indepth conference program to learn about topics from new. Axiflux is the creator of the adaptive magnetic flux array amfa, the worlds first modular, realtime, softwarereconfigurable electric motor and generator. This is a permanent magnet stepper motor that is also an axial flux motor.
Axialflux motors and generators shrink size, weight power. We are an industry leader in pmac motors, controls, and power transmission products for the commercial hvac industry. As an alternator this unit produces threephase 220 vac, 3300 watts, at 180 rpm. Flux is a finite element software used for 2d and 3d electromagnetic and electrotermal analysis. Analysis and simulation of singlephase and twophase. Once the geometry has been easily selected from the library, materials are set and windings are added by completing a simple table corresponding to. Which makes this axial flux, direct drive motor from belgian company magnax a real eyebrowraiser. On a radial flux bldc motor, the magnets are positioned such that their poles lie radially at the outer edge of the rotor. Axial flux motors, on the other hand, offer the lowest possible copper loss. The design of the direct drive inwheel motor is shown in fig. The axial flux motors have flux that runs parallel to the output shaft along the axis of the shaft, thus, axial. Belgium startup magnax is considering three main markets for its newlydesigned axial flux bldc motors. Therefore the designers face a lot of difficulties in designing and optimizing the motor for a given application. This paper presents a comparison of two different kinds of bldc motors for application in handheld power tool drives.
On the other hand, an analysis was conducted to compare the efficiency of radial and axial flux for permanent magnet brushless dc pm bldc motor 22. Magnax says the key to the high power density is its motors yokeless af design with two rotors at each side of the machine. Technology yokeless axial flux motors for electric vehicles. Our af motor axial flux motor if the low torque permanent magnet motor within the eta motors range. The yokeless, permanentmagnet topology offers greater efficiency around the motor s central axis, and wastes very little copper on windings because the motors have zero overhang.
The motor design was simulated by using ansoft maxwell3d electromagnetic simulation finite element method fem software to get certain parameters. Designed by msftechnologies for electric and hybrid drive. Motor, bldc motor, pm motor, motor design its important first to understand blpm motors. Results of the fea simulation were compared with those obtained from the sizing equation. Bldc is a comprehensive brushless dc design environment. It enables engineers to easily design their machines from standard, customized and parametric parts, add windings with multilevel assistant and attribute materials to quickly run a selection of tests and compare their performance. Magnax offers a new concept, thougha machine that operates with axial flux af. Primarily for hi torque medium speed propellers, this particular one i would hope to be around 1kw. Avid technology designs and manufactures permanent magnet radial flux motors, sometimes called bldc motors. Those are not bldc, they are stepper motors and work on a completely different principle. Figure 1 provides a comparison of the rf and af technologies.
The axial flux enables high power densities to be achieved at relatively low speeds 20009000rpm, making the motors ideally suited to hybrid and generation applications. The yokeless, permanentmagnet topology offers greater efficiency around the motors central axis, and wastes very little copper on windings because the motors have zero overhang. This axial flux permanent magnet motor is designed to achieve a high torquetoweight ratio and motor efficiency, and is suitable for the directdriven wheel applications. Why arent axial flux motors dc or ac very popular or. The design of the machine was developed with a mathematical mode of axial flux permanent magnet synchronous generator. New axial flux electric motors pack more ev power in a. Magnax has spent six years developing its axial flux motors. Nov 17, 2016 axial flux induction motor for automotive applications hybrid and electric vehicle technology has seen rapid development in recent years. To study the motor operation, a mathematical dynamic model has been proposed for each of the motor with different winding, which became the basis for simulations that were performed using matlabsimulink software package. Permanent magnet axial flux motors allow the axial. Design of axial flux permanent magnet brushless dc motor. May 21, 2018 the downside to a radial flux bldc motor is its size and weight. Jun 28, 2007 this paper presents the design of an electric motor for the direct drive of electric vehicle.
Magnax says the key to the high power density is its motors yokeless af design with two rotors at each side of the. Why arent axial flux motors dc or ac very popular or common. Ranging from 500w up to 20kw and across a range of operating voltage levels. Radial flux motors permanent magnet avid technology. This paper discusses a three phase axial flux outer rotor bldc motor, but the core equations can be easily changed to simulate for any kind of.
Whereas radial flux machines are well known and broadly used, the axial flux concept is less popular. Especially in multi motor drive train configurations, the freespinning or noload losses reduce the effective range of the vehicle by 10% to 20%. I found that there are plenty software that will do the sizing and magnetic analysis for radial flux machine, but nothing for axial flux machine. The company is looking carefully at the transportation sector, particularly mainstream electric vehicles, motorcycles, and aviation. With the use of flux fea software, design cost and time can be decreased. Software design tool for optimum axial flux bldc motors. Industrial servomotors design of dc and ac permanent magnet servomotors bldc and blac motors can be performed at mds motor design ltd. One reason may be the more complex design process and the need to use 3dfem calculation.
Design, control and evaluation of a prototype three phase. The motor and generator are at the heart of the vehicle drive and energy system and often utilise expensive rareearth permanent magnet material. Software design tool for optimum axial flux bldc motors semantic. Design of axial flux permanentmagnet lowspeed machines and performance comparison between radial flux and axial flux machines lappeenranta 2005 153 p. Axial flux induction motor for automotive applications. It includes analysis of both the drive circuit and the electric machine itself and is carried out simultaneously and entirely within bldc. Furthermore, a comparative study between conventional rfpm and. Design and analysis of permanent magnet brushless dc motor. Compared with traditional permanent magnet ev motors, magnax yokeless axial flux motors come with 85% less iron cores losses and up to 4 times less iron iron mass compared with traditional ev motors. Today, most electric machines operate with radial flux rf.
The simplest eddy examiner is just twoside multipole rotor of axial flux motor wheres few mm airgap. Generalized procedure for bldc motor design and substantiation in magnet 7. Because of this they are suitable for a range of highperformance drivetrain applications. The axial flux enables high power densities to be achieved at relatively low speeds 20009000rpm, making the motors ideally suited to hybrid and. Inhub motors today can be configured as inner rotation, outer rotation, or axial flux devices. Design and fabrication of axial flux ferrite magnet. Design and simulation an axial flux permanent magnet motor is different from a conventional electric motor due to the path of magnetic flux inside the motor. In other words, more of the battery power gets turned into useful motor. Relative to a traditional electrical motor, the innovative configuration and control of the amfa yields significant size, weight and price reductions, while increasing power. Axial flux motors as a genre are a very specific set of machines. Whether designing an electric motor for an electric vehicle that needs to be small, efficient and quiet, or for an industrial application where size and sound are not of major concern, it is critical to simulate electric motors early in the design process.
This paper presents a new method to optimize the performance in speed, torque, torque stability, power output, power density and motor dimensions in view of the cost and reliability for a. Ce moteur a ete developpe dans le cadre dun projet l. The basic benefit comes in from the possibility of grain oriented steel u. These machines as a motor or as a generator are more efficient than their radial flux machines siblings. Derived principally from pump and industrial motor designs, the robust design. Hvac commercial innovation ecm motor fan and blower innovation. Dunkermotoren breaks the mold with its brushless dc motor development. Powerful, efficient and reliable bldc motors we are leading manufacturer of generalpurpose brushless dc bldc motors with power range from 200w to 20kw, and the voltage range from 24v to 120v dc. Actually i did not finished this axial version because mechanical problems very strong magnetic force needs very heavyduty rotor design. Fluxmotor is a flexible software solution dedicated to the predesign of electric motor.
The analysis proves that axial flux motor gives higher efficiency of 89. Data from the experimental tests were obtained and the results were compared to the simulation results. This paper discusses a three phase axial flux outer rotor bldc motor, but. Quickly decided on axial flux layout because of the hi torque, relative ease of construction and high energy density along with being able to operate. Design and comparison of radial flux and axial flux. This paper discusses a three phase axial flux outer rotor bldc motor, but the core. Meanwhile, table 2 shows details construction of slots in the stator side. A software interface and simulation results are presented to check the level of optimization achievable with the system.
Magnax claims it makes a peak power no less than 15 kwkg, with the ability to produce sustained. Axial flux motor stator configuration and materials rc. The air gap the space between the rotor and the magnets can also describe the motor, but. Just a motor that can take a controlled number of steps. To meet the market demand with an attractive costbenefit ratio, dunkermotoren has developed a new axial flux motor design with stacked windings. The yasa 750, yasa p400 series and yasa 400 axial flux motors achieve power densities of up to 10kwkg and torque densities which are significantly better than the nearest competitive motor topology. Preliminary design for a motor with 16 rotor poles was chosen in order to achieve high torque density and stable rotation at low speed. Magnax prepares to manufacture radically highpowered. We are leading manufacturer of generalpurpose brushless dc bldc motors with power range from 200w to 20kw, and the voltage range from 24v to 120v dc. Magnax yokeless axial flux motors for electric vehicles. The design s dual rotors allow the use of grainoriented magnetic steel that magnax claims can lower core losses by as much as 85% for improved efficiency. There are several analytical approaches developed at various universities worldwide. This paper simulation can be used to optimize a full range of bldc discusses a three phase axial flux outer rotor bldc motor, but motors. Design of axial flux pm disc motors for electric vehicle applications is one of our areas of expertise.
Axialflux motors and generators shrink size, weight. Finite element method fem is used for determining the performance characteristics of motor. Designs and prototypes of fullsize axial flux and radial flux electric tail rotor motors were delivered, including comprehensive test data and supporting analyses. Design and analysis of permanent magnet brushless dc. The brushless pm motors perform better and have higher efficiency than the machines with electro. Autocad inventor 3d cad software was used by me to design 3d model of the motor. From the outset, the design team targeted leed gold and china 3 star ratings.
Figure 1 provides a comparison of the rf and af technologies 1. The goal of the designers was to create an architectural jewel that was as energy efficient as it is beautiful. Analysis of axial flux bldc motor in this section will perform the design of the bldc motor stator axial flux using 3d design software. A sustainable design was at the core of shanghai towers development. A permanent magnet motor was designed in the form of an axial flux inner statornon slot type. Ashwoods axial flux motors are permanent magnet, brushless ac motors that power a range of applications at both low and high volumes in specialist markets.
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